Yamaha WaveRunner GP1300R Manual

SUPPLEMENTARY

SERVICE MANUAL

GP1300R

WaveRunner

F1G-28197-1G-1XLIT-18616-02-90

*LIT186160290*

NOTICE

This Supplementary Service Manual has been prepared to introduce new service and new data

information for the GP1300R which are based on the 2003 GP1300R. For complete information on

service procedures, it is necessary to use this Supplementary Service Manual together with the fol-

lowing manual.

GP1300R SERVICE MANUAL: F1G-28197-1F-11 (LIT-18616-02-44)

A10001-0*

WaveRunner GP1300R

SUPPLEMENTARY SERVICE MANUAL

1st Edition, October 2004

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, USA

is expressly prohibited.

Printed in USA

LIT-18616-02-90

HOW TO USE THIS MANUAL

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-

tion has been compiled to provide the mechanic with an easy to read, handy reference that contains

comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the

course of action required will follow the symbol, e.g.,

•Bearings

Pitting/scratches → Replace.

To assist you in finding your way through this manual, the section title and major heading is given at

the top of every page.

ILLUSTRATIONS

The illustrations within this service manual represent all of the designated models.

CROSS REFERENCES

The cross references have been kept to a minimum. Cross references will direct you to the appropri-

ate section or chapter.

IMPORTANT INFORMATION

In this Service Manual particularly important information is distinguished in the following ways.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine

operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the water-

craft.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT:

This part has been subjected to change of specification during production.

HOW TO USE THIS MANUAL

1To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

2Numbers are given in the order of the jobs in the exploded diagram.

3Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

4A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

5Dimension figures and the number of parts, are provided for fasteners that require a tightening

torque.

Example:

Bolt or screw size : M10 (D) ×25 mm (L)

6Jobs requiring more information (such as special service tools and technical data) are described

sequentially.

10 ×25 mm

A50001-1-4

SYMBOLS

Symbols 1to 9are designed to indicate the

content of a chapter.

1General Information

2Specifications

3Periodic Inspection and Adjustment

4Fuel System

5Power Unit

6Jet Pump Unit

7Electrical System

8Hull and Hood

9Trouble Analysis

Symbols 0to Eindicate specific data.

0Special service tool

ASpecified oil or fluid

BSpecified engine speed

CSpecified tightening torque

DSpecified measurement

ESpecified electrical value

(resistance, voltage, electric current)

Symbols Fto Hin an exploded diagram indi-

cate the grade of lubricant and the lubrication

point.

FApply Yamaha 2-stroke motor oil

GApply water resistant grease

(Yamaha grease A, Yamaha marine grease)

HApply molybdenum disulfide grease

Symbols Ito Nin an exploded diagram indi-

cate the type of sealant or locking agent and

the application point.

IApply Gasket Maker

JApply Yamabond No. 4

KApply LOCTITE 271 (red)

LApply LOCTITE 242 (blue)

MApply LOCTITE 572

NApply silicone sealant

NOTE:

Additional symbols may be used in this man-

ual.

GEN

INFO SPEC

INSP

ADJ FUEL

POWR

JET

PUMP

–+

ELEC

HULL

HOOD

TRBL

ANLS

A M

271

242

572

LT SS

INDEX

GENERAL INFORMATION 1

GEN

INFO

SPECIFICATIONS 2

SPEC

PERIODIC INSPECTION AND

ADJUSTMENT 3

INSP

ADJ

FUEL SYSTEM 4

FUEL

POWER UNIT 5

POWR

JET PUMP UNIT 6

JET

PUMP

ELECTRICAL SYSTEM 7

ELEC

HULL AND HOOD 8

HULL

HOOD

TROUBLE ANALYSIS 9

TRBL

ANLS

–+

A30000-0

GENERAL INFORMATION

IDENTIFICATION NUMBERS ............................................................................ 1

PRIMARY l.D. NUMBER .............................................................................. 1

ENGINE SERIAL NUMBER ......................................................................... 1

JET PUMP UNIT SERIAL NUMBER ............................................................ 1

HULL IDENTIFICATION NUMBER (H.l.N.).................................................. 1

SPECIAL SERVICE TOOLS .............................................................................. 2

REMOVAL AND INSTALLATION................................................................. 3

SPECIFICATIONS

GENERAL SPECIFICATIONS .......................................................................... 4

MAINTENANCE SPECIFICATIONS .................................................................. 6

ENGINE ....................................................................................................... 6

JET PUMP UNIT ......................................................................................... 7

HULL AND HOOD ....................................................................................... 8

ELECTRICAL ............................................................................................... 8

TIGHTENING TORQUES ................................................................................. 11

SPECIFIED TORQUES.............................................................................. 11

GENERAL TORQUE .................................................................................. 16

CABLE AND HOSE ROUTING ........................................................................ 17

PERIODIC INSPECTION AND ADJUSTMENT

MAINTENANCE INTERVAL CHART ............................................................... 26

JET PUMP UNIT

IMPELLER DUCT AND IMPELLER HOUSING 1 ............................................ 27

EXPLODED DIAGRAM .............................................................................. 27

REMOVAL AND INSTALLATION CHART ................................................. 27

IMPELLER DUCT AND DRIVE SHAFT ........................................................... 29

EXPLODED DIAGRAM .............................................................................. 29

REMOVAL AND INSTALLATION CHART ................................................. 29

SERVICE POINTS ..................................................................................... 31

Drive shaft removal .............................................................................. 31

Impeller inspection ............................................................................... 33

Drive shaft inspection........................................................................... 33

Drive shaft installation.......................................................................... 33

ELECTRICAL SYSTEM

ELECTRICAL COMPONENTS......................................................................... 36

IGNITION SYSTEM .......................................................................................... 37

WIRING DIAGRAM .................................................................................... 37

SENSOR ASSEMBLY ................................................................................ 39

SLANT DETECTION SWITCH ................................................................... 39

OFF THROTTLE STEERING SYSTEM............................................................ 40

WIRING DIAGRAM .................................................................................... 40

STEERING SENSOR ................................................................................. 41

HULL AND HOOD

STEERING COLUMN....................................................................................... 42

EXPLODED DIAGRAM .............................................................................. 42

REMOVAL AND INSTALLATION CHART ................................................. 42

SERVICE POINTS ..................................................................................... 46

Steering column assembly................................................................... 46

EXHAUST SYSTEM ......................................................................................... 47

SERVICE POINTS ..................................................................................... 47

Exhaust component parts assembly .................................................... 47

TROUBLE ANALYSIS

TROUBLE ANALYSIS...................................................................................... 48

SELF-DIAGNOSIS ..................................................................................... 48

WIRING DIAGRAM

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